Structural cells, matrices and methods of assembly

ABSTRACT

Structural cells and matrices using the structural cells for positioning below a hardscape that define a void space therein, the structural cells, matrices using the cells and methods of assembly allowing in one embodiment the introduction of a structural fluid such as concrete to provide an alternative structural cell and matrix product. In one embodiment a structural cell assembly is described comprising a structural cell with a plurality of legs integrally linked to a frame at a first frame end, the frame linking the legs together and the frame defining a generally flat plane with the legs extending substantially orthogonally away from the first frame end about the frame flat plane to a leg terminal end; and a separate plate engaging the legs, the separate plate comprising linked sockets, each socket engaging the leg terminal end; and/or linked sockets, each socket engaging the leg frame ends or a part thereof.

TECHNICAL FIELD

Described herein are improvements in structural cells, matrices andmethods of assembly. More specifically, structural cells and matricesusing the structural cells are described for positioning below ahardscape that define a void space therein, the structural cells,matrices using the cells and methods of assembly allowing in oneembodiment the introduction of a structural fluid such as concrete in apart of parts of the cell to alter the structural cell and matrixproduct characteristics.

BACKGROUND ART

Structural cells for under hardscapes that support a compressive loadhave been used for a number of years now. Art products are typicallyplastic mouldings using spaced apart legs and a base, top or otherretraining structure to align the legs. The legs take up compressiveloading on the cell allowing the void space inside the cell to be usedfor applications such as tree root growth in uncompacted soil or, waterreservoir use where the void space is used to capture and retain stormwater. There can also be other uses for structural cells or matricesusing the structural cells where void space is needed in order to fill avolume and where some degree of structural strength and integrity isrequired—one example might be in the construction of roadside bermswhere structural cell matrices may provide an alternative totransporting and delivery of significant volumes of infill.

One drawback of existing designs may be complexity. Another drawback maybe in cost. A further drawback may be in structural strength achievedfrom plastic. Another drawback may be a perceived lack of structuralcapability in civil and structural applications from a material likeplastic. A further drawback may be that of plastic deflection wherebyplastic art cells may move elastically when placed under load which isan issue when brittle or non-elastic materials are coupled with thecells and matrices.

The structural cells, matrices and methods of assembly described hereinattempt to address at least some of the above drawbacks or at leastprovide the public with a choice.

Further aspects and advantages of the structural cells, matrices andmethods of assembly will become apparent from the ensuing descriptionthat is given by way of example only.

SUMMARY

Structural cells and matrices using the structural cells are describedherein for positioning below a hardscape that define a void spacetherein, the structural cells, matrices using the cells and, methods ofassembly, allowing in one embodiment the introduction of a structuralfluid such as concrete to provide an alternative structural cell andmatrix product.

In a first aspect, there is provided a structural cell assembly, theassembly comprising:

-   -   a structural cell with a plurality of legs integrally linked to        a frame at a first frame end, the frame linking the legs        together and the frame defining a generally flat plane with the        legs extending substantially orthogonally away from the first        frame end to a leg terminal end; and    -   a separate plate engaging the legs, the separate plate        comprising:    -   linked sockets, each socket engaging the leg terminal end;        and/or    -   linked sockets, each socket engaging the leg frame ends or a        part thereof.

In a second aspect, there is provided a structural cell formwork that isconfigured to receive and retain a structural fluid therein, thestructural cell comprising:

-   -   a plurality of hollow legs integrally linked to a frame at a        first frame end, the frame linking the legs together and the        frame defining a generally flat plane with the legs extending        substantially orthogonally away from the first frame end to a        leg terminal end; and    -   wherein the frame and hollow leg interior collectively define an        internal void space that receives and retains a structural fluid        placed therein.

In a third aspect, there is provided a load bearing matrix comprising:

-   -   a plurality of structural cells aligned vertically and/or        horizontally; and    -   a plurality of separate plates, each separate plate being        approximately the same width and length as each structural cell,        the separate plates located on top of the plurality of        structural cells and/or below the plurality of structural cells;        and    -   wherein each structural cell comprises a plurality of legs        integrally linked to a frame at a first leg frame end, the frame        defining a generally flat plane with the legs extending        substantially orthogonally away from the first leg frame end to        a leg terminal end; and    -   wherein each separate plate comprises plate sockets linked        together via lateral connectors that engage with either an        opening in the first leg frame end of a first structural cell,        or the leg terminal end of a second structural cell.

In a fourth aspect, there is provided a structural cell formed fromhardened structural fluid, the structural cell comprising:

-   -   a plurality of solid legs linked to a frame at a first frame        end, the frame defining a generally flat plane with the legs        extending substantially orthogonally away from the first frame        end to a leg terminal end; and wherein the structural cell        defines a free void space therein, the free void space defined        by the frame width and depth and the leg height, less any space        used within this volume for the legs or frame parts.

In a fifth aspect, there is provided a load bearing matrix comprising:

-   -   a plurality of structural cells stacked vertically and/or        horizontally wherein each structural cell is formed as one        element from hardened structural fluid, each structural cell        comprising:    -   a plurality of solid legs linked to a frame at a first frame        end, the frame defining a generally flat plane with the legs        extending substantially orthogonally away from the first frame        end to a leg terminal end; and wherein the structural cell        defines a free void space therein, the free void space defined        by the frame width and depth and the leg height, less any space        used within this volume for the legs or frame parts.

In a sixth aspect, there is provided a method of forming a load bearingmatrix, the method comprising the steps of:

-   -   select at least one structural cell substantially as described        above and a substrate on which the load bearing matrix will be        formed;    -   place separate plates on the substrate;    -   place a first layer of structural cells on the separate plates;    -   repeat placing of structural cell layers vertically until the        desired matrix height is reached;    -   place separate plates on top of the final structural cell layer;        and optionally,    -   placing a load on the matrix.

Advantages of the above may include elimination of deflection of thelegs or other cell parts when the cell or matrix of cells are subjectedto a compressive load. Deflection using art products may be very low butthis still may be of some importance when used beneath pavementssubjected to unrestricted or dynamic vertical loads. The structural celldescribed may better withstand compressive loads and may be filled witha structural fluid like concrete in order to completely prevent anyvertical deflection at all. Concrete in particular may represent auseful structural fluid since it is well understood and widely used andaccepted in structural applications.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aspects of the structural cells, matrices and methods ofassembly will become apparent from the following description that isgiven by way of example only and with reference to the accompanyingdrawings in which:

FIG. 1 illustrates an exploded perspective view of one configuration ofstructural cell matrix;

FIG. 2 illustrates an exploded perspective view of an alternativeconfiguration of a structural cell matrix;

FIG. 3 illustrates an embodiment of a perspective view from above of a3×3 leg configuration frame and legs;

FIG. 4 illustrates the 3×3 frame and leg arrangement above in a planview;

FIG. 5 illustrates the 3×3 frame and leg arrangement above in a sideview;

FIG. 6 illustrates a perspective view of a free collar;

FIG. 7 illustrates a perspective view of a separate frame;

FIG. 8 illustrates a plan view of a matrix comprising four 3×3 frame andleg units and a detail view D;

FIG. 9 illustrates a side view of the matrix above and a detail view A;

FIG. 10 illustrates a perspective view from above of a part assembledmatrix;

FIG. 11 illustrates detail E noted in FIG. 10 above;

FIG. 12 illustrates detail C noted in FIG. 9 above;

FIG. 13 illustrates a perspective view from above of an alternative partassembled matrix; and

FIG. 14 illustrates a side view of the alternative part assembled matrixof FIG. 13 and detail A.

DETAILED DESCRIPTION

As noted above, described herein are structural cells and matrices usingthe structural cells for positioning below a hardscape that define avoid space therein, the structural cells, matrices using the cells, andmethods of assembly, allowing in one embodiment the introduction of astructural fluid such as concrete to provide an alternative structuralcell and matrix product.

For the purposes of this specification, the term ‘about’ or‘approximately’ and grammatical variations thereof mean a quantity,level, degree, value, number, frequency, percentage, dimension, size,amount, weight or length that varies by as much as 30, 25, 20, 15, 10,9, 8, 7, 6, 5, 4, 3, 2, or 1% to a reference quantity, level, degree,value, number, frequency, percentage, dimension, size, amount, weight orlength.

The term ‘substantially’ or grammatical variations thereof refers to atleast about 50%, for example 75%, 85%, 95% or 98%.

The term ‘comprise’ and grammatical variations thereof shall have aninclusive meaning—i.e. that it will be taken to mean an inclusion of notonly the listed components it directly references, but also othernon-specified components or elements.

The term ‘cell’ and ‘structural cell’ and grammatical variations thereofare used interchangeably and reference to one or the other should not beseen as limiting.

The term ‘matrix’ and grammatical variations thereof refers to multiplestructural cell aligned in a horizontal plane, aligned in a verticalplane and/or aligned in both a horizontal and vertical plane.

Structural Cell Assembly

In a first aspect, there is provided a structural cell assembly, theassembly comprising:

-   -   a structural cell with a plurality of legs integrally linked to        a frame at a first frame end, the frame linking the legs        together and the frame defining a generally flat plane with the        legs extending substantially orthogonally away from the first        frame end to a leg terminal end; and    -   a separate plate engaging the legs, the separate plate        comprising:    -   linked sockets, each socket engaging the leg terminal end;        and/or    -   linked sockets, each socket engaging the leg frame ends or a        part thereof.

Structural Characteristics

The structural cell may resist a compressive load imposed about the leglongitudinal axis or plurality of leg axes.

The structural cell absent of any structural fluid (described in moredetail below) may have a crush resistance or compressive strength of atleast approximately 100, or 125, or 150, or 175, or 200, or 225, or 250,or 275, or 300, or 325, or 350, or 375, or 400, or 425, or 450, or 475,or 500, or 525, or 550, or 575, or 600 kPa. The structural celldescribed may have a compressive strength of greater than 150 kPa.Alternatively, the structural cell described may have a compressivestrength of greater than 300 kPa. The exact compressive strength maydepend on the final application—low load bearing applications may forexample require minimal compressive strength while high load bearingapplications, such as a roadway bearing heavy vehicles, may requiresignificantly more compressive strength. The use or otherwise of astructural fluid in the cell (described further below) may also havesome bearing on the compressive strength of the cell described herein.As described further below, the structural cell may have an additionalstructural fluid added and the structural cell itself may merely act toreceive and retain the structural fluid, at least until hardening orsetting, and may not itself provide any significant structural loadcapacity to the hardscape. In this embodiment, the structural cellitself may even have a compressive strength below 100 kPa. As may beappreciated, art structural cells may achieve similar (or lower)compressive strength however, the inventor has found that the materialvolume required to form the structural cells described herein is farmore efficient relative to compressive strength. By way of example, theinventor has found that art structural cells which achieve compressivestrengths of 150 kPa or 300 kPa using 10, or 15, or 20, or 25, or 30, or35, or 40, or 45, or 50% more material volume than a similar structuralcell described herein for the same compressive strength rating. Thismaterial volume (usually plastic) saving equates to significant costbenefits in terms of materials used to manufacture the cells and, alsoconsiderably faster manufacture (perhaps up to 20% faster manufacturingspeed in the inventor's experience).

The compressive strength noted above may be measured by placing astructural cell between two steel plates of a similar or greater area asthe cell width and depth. The steel plates used may typically be 20-30mm thick. The steel plate weights may apply a fixed measurable forceload/pressure to the cell between the steel plates. Additional forceload/pressure may then be applied to the structural cell between thesteel plates until at least partial collapse/plastic deformation of thestructural cell occurs. The load or pressure at which collapse/plasticdeformation occurs may be defined as being the compressive strength ofthe structural cell.

As may be appreciated, compressive strength as measured above is not aperfect measure of structural cell integrity as, at least a degree ofelastic deformation may occur to the structural cell prior tocollapse/plastic deformation. The true structural strength if elasticdeformation is used as a primary measure, may in fact be 5, or 10, or15, or 20, or 25, or 30% lower than the measured compressive strength atwhich collapse occurs. As a result, where deflection is to be avoided,the compressive strength of art plastic cells may be significantlyoverstated.

The structural cell described herein may be designed, even without astructural fluid, to minimise elastic deformation or deflection so thatthe structural cell resists elastic deformation/deflection up to a pointaround 20, or 15, or 10, or 5% below the final compressive strength whencollapse/plastic deformation occurs. Whilst not wanting to be bound totheory, it is understood that at least in part, this additionalresistance to deflection may be due to way the frame of the structuralcell described herein is arranged relative to the legs and/or thecircular/conical leg shape acting to efficiently transfer a load to theframe/cell.

The structural cell may at least partly bear the load of a hardscapeplaced on the structural cell.

The structural cell may at least partly bear a load applied by an objecton a hardscape placed over the structural cell.

Alternatively, the structural cell may bear the load of a structuralfluid poured therein.

Void Space

The overall structural cell shape may be substantially defined by theextent of the frame width, depth and the leg length. There may be noother items or parts present about the structural cell height other thanthe legs. When viewed side on, each structural cell may presentunobstructed openings or void space completely through the structuralcell between the legs.

The overall structural cell volume may be defined by a free void space,an internal void space and a portion of structural cell material itself.

The free void space may be the space defined by the frame width anddepth and the leg height less any space used within this volume for thelegs or frame parts and any internal void space within the legs andframe.

The internal void space may be defined by any volume of space within thelegs or frame not accessible from within the free void space. As shouldbe appreciated, none of the leg volume may be accessible from the freevoid space if the legs are continuous in form along their length, forexample being solid legs or alternatively being hollow legs but withoutany openings accessible from inside the free void space. Alternatively,at least some of the leg volume may be accessible to the free void spaceif the leg or legs are hollow internally and if an opening existed inthe leg sides for example. Either option may be possible depending onthe desired end configuration and outcome.

The free void space may be at least approximately 75, or 76, or 77, or78, or 79, or 80, or 81, or 82, or 83, or 84, or 85, or 86, or 87, or88, or 89, or 90% of the overall structural cell volume. The structuralcell free void space may be approximately 75-85%, or 80-85%, or 85-90%of the overall structural cell volume.

The internal void space may be at least approximately 1, or 2, or 3, or4, or 5, or 6, or 7, or 8, or 9, or 10, or 11, or 12, or 13, or 14, or15, or 16, or 17, or 18, or 19, or 20, or 21, or 22, or 23, or 24, or25% of the overall structural cell volume. The structural cell internalvoid space may be approximately 15-25%, or 10-15%, or 5-10%, or 1-5% ofthe overall structural cell volume.

Number and Leg Configuration

The structural cell may have multiple legs, the legs arranged relativeto each other in regular or even patterns that collectively spread acompressive load placed on the structural cell frame.

The structural cell may have two legs. The two legs may be arrangedbeside each other in a common vertical plane.

The structural cell may have three legs. The three legs may be arrangedbeside each other in a common vertical plane. The three legs mayalternatively be arranged to form a triangular shape about a horizontalplane.

The structural cell may have four legs. The four legs may be arrangedbeside each other in a common vertical plane. The four legs mayalternatively be arranged to form a square shape about a horizontalplane.

The structural cell may have five legs. The five legs may be arrangedbeside each other in a common vertical plane. The five legs mayalternatively be arranged to form a pentagon shape about a horizontalplane.

The structural cell may have six legs. The six legs may be arrangedbeside each other in a common vertical plane. The six legs mayalternatively be arranged to form a rectangular shape about a horizontalplane. The six legs may alternatively be arranged to form a triangularshape about a horizontal plane. The six legs may alternatively bearranged to form a hexagon shape about a horizontal plane.

The structural cell may have nine legs. The nine legs may be arrangedbeside each other in a common vertical plane. The nine legs mayalternatively be arranged to form a square shape about a horizontalplane.

The structural cell may have ten or more legs, the legs arranged inrepeating patterns that evenly spread a compressive load placed thereon.

Leg Shape

The legs may be substantially round or elliptical in cross-section andtubular in length.

The tubular legs may be conical. The tubular legs may alternatively beat least in part frustoconical along the leg length.

Alternatively, the legs may be polygonal in cross-section at least inpart along the leg length. The polygonal leg cross-section may betriangular, square, pentagonal, hexagonal, octagonal and so on.

The structural cell legs may have a common cross-sectional form alongthe leg length.

The structural cell legs may have a varying cross-sectional form alongthe leg length.

Reference within this specification to ‘diameter’ should not be seen aslimiting to purely circular cross-sections. As noted above, thecross-section shape may vary and diameter as a term is used hereafterfor prolixity to cover various shapes and forms.

The legs may be widest about the first frame end and narrowest at theterminal end. In one embodiment, the widest leg diameter may be lessthan 12, or 11, or 10, or 9, or 8 inches and the narrowest leg diametermay be less than 8, or 7, or 6 inches. In one embodiment, the widestdiameter may be around 7.5 inches and the narrowest diameter may bearound 5.5 inches however the exact dimensions may vary considerablybetween designs.

The legs may be at least partly hollow. The legs may be at leastpartially open at: the leg frame end; the leg terminal end; both the legframe end and the leg terminal end.

The legs may be generally straight although, non-straight e.g. bent legscould also be used. Straight legs may be useful to efficiently transfera compressive load force along the leg length.

Structural Cell Leg Length

The structural cell legs may have a common length.

The leg length may be fixed, each leg being a continuous integralcomponent.

The structural cell leg length may alternatively be adjustable. Leglength may for example be adjusted using a telescoping assembly. Leglength may alternatively be adjusted by fitting an additional legsection to a first leg section.

The structural cell leg length may be approximately 150, or 175, or 200,or 225, or 250, or 275, or 300, or 325, or 350, or 375, or 400% of thestructural cell leg first end diameter. The structural cell leg lengthmay be approximately 5, or 6, or 7, or 8, or 9, or 10, or 11, or 12, or13, or 14, or 15, or 16, or 17, or 18, or 19, or 20, or 21, or 22, or23, or 24, or 25, or 26, or 27, or 28, or 29, or 30 inches long. Thestructural cell leg may for example be 5-30 inches long. In oneembodiment, the structural cell leg length may be approximately 5-15, or8-12, or around 10 inches long. In an alternatively embodiment, the leglength may be approximately 15-25, or 16-23, or 17-21, or around 20inches long.

Frame and Leg are Integral

The structural cell legs and frame may be one material formed togetheri.e. integral.

The legs may be moulded with the frame as one element.

Frame Generally and Frame Function

The frame may link the legs together via lateral supports located aboutthe first frame end of each leg. The frame may have a top forming asubstantially flat plane that may be generally in a horizontalorientation in anticipated applications but may be angled relative to ahorizontal plane if desired (e.g. by up to 1, or 2, or 3, or 4, or 5degrees), for example to account for substrate angle variations such asuneven ground.

The frame may define the position of each leg relative to each otherleg, fixing the leg in position within the overall structural cellvolume.

The frame may spread a compressive point load across the structural celllegs. The frame may provide greater rigidity to a structural cell matrixwhen multiple structural cells are used together. The greater rigiditymay prevent the structural cell legs from deforming or moving such assplaying or buckling when under a compressive load.

Frame Lateral Supports

In a generally vertical planar leg configuration, each frame lateralsupport may meet each leg frame end at approximately 180 degrees to eachother lateral support.

In generally square or rectangular leg arrangements, each frame lateralsupport may meet each leg frame end at right angles to each otherlateral support.

In circular or rounded leg frame arrangements, each frame lateralsupport may meet each leg frame end at approximate right angles—usuallywithin the range of 70-110 degrees to each other lateral support.

Each lateral support may be elongated and narrower in width than firstframe end leg diameter size.

Each lateral support may be linear and straight along the elongatedlength.

Each lateral support may be non-linear and varies in straightness alongthe elongated length.

Each lateral support may have an arc shape along the elongated length.

Frame and Frame Lateral Support Dimensions

Each lateral support may have a width that is approximately 25, or 30,or 35, or 40, or 45, or 50, or 55, or 60, or 65 or 70, or 75% of thediameter of the first frame end of the leg. The lateral support widthmay be from 25-75%, or 40-60%, or 45-55% or approximately 50% of thediameter of the first frame end of the leg.

Each lateral support may have a length from leg frame side to leg frameside that is approximately 50, or 55, or 60, or 65, or 70, or 75, or 80,or 85, or 90, or 95, or 100, or 105, or 110, or 115, or 120, or 125, or130, or 135, or 140, or 145, or 150% that of the diameter of the firstframe end of the leg. The lateral support length from leg frame side toleg frame side may be approximately 50-150%, or 75-125%, or 90-110%, orapproximately 100% of the diameter of the first frame end of the leg.

In one embodiment of a 3×3 leg square configuration, the frame width maybe approximately 30, or 31, or 32, or 33, or 34, or 35, or 36, or 37, or38, or 39, or 40 inches wide and deep. The frame width and depth may beapproximately 30-40 inches, or 32-38 inches, or 35-37 inches, orapproximately 36 inches square.

Other square configurations such as a 2×2 leg square configuration mayhave a smaller proportional size or larger square configurations such asa 4×4 leg square configuration may have a larger proportional size.

Cell Height

The overall cell height from the terminal end of a leg to the top of theplanar form defined by the top of the frame such as a frame lip or lipsmay be approximately 150, or 175, or 200, or 225, or 250, or 275, or300, or 325, or 350, or 375, or 400% of the cell leg frame end diameter.The cell height may be approximately 5, or 6, or 7, or 8, or 9, or 10,or 11, or 12, or 13, or 14, or 15, or 16, or 17, or 18, or 19, or 20, or21, or 22, or 23, or 24, or 25, or 26, or 27, or 28, or 29, or 30 incheshigh. The structural cell height may for example be 5-30 inches high. Inone embodiment, the structural cell height may be approximately 5-15, or8-12, or around 10 inches high. In an alternatively embodiment, thestructural cell height may be approximately 15-25, or 16-23, or 17-21,or around 20 inches high.

As may be appreciated from the above frame dimensions and cell heightdimensions, the structural cell described herein may be proportionatelylarger than some art products. Whilst not being limited to the largersizes noted, a larger structural cell size may be beneficial as this mayspeed manufacture through fewer units being required, larger moreaccessible tooling, faster installation on site, and potentially areduction in the amount of plastic needed for a given matrix volume.

Frame Formwork Detail

The frame lateral supports, leg frame end surrounds and legs maycollectively define a common hollow, this hollow defining an internalvoid space.

The hollow may be bound by an extended lip or lips about the lateralsupports and/or leg frame end surrounds.

The common hollow may be the entire volume within all of the lateralsupports and leg ends. The common hollow may instead be regions of thelateral supports and/or leg frame ends. The common hollow may besegregated into different regions for example using at least one spar orrib.

The frame end of each leg may open into the legs themselves, the hollowthen defined by both the leg opening as well as any hollows defined bythe leg frame end and lateral supports.

The hollow or hollows may define a volume configured to receive andretain a structural fluid therein.

The extended lip or lips of the frame may terminate at a common point soas to form a substantially planar finish.

The extended lip or lips may follow the perimeter of all of the framelateral supports and leg frame endings.

The hollow may open in a direction opposite the direction in which thelegs extend orthogonally away from the frame.

Structural Fluid

The structural cell may be configured to receive and retain a structuralfluid. The structural fluid may be placed into the structural cellinternal void space or hollow as noted above.

The structural fluid may be poured as a liquid or semi-liquid into thecommon socket or sockets and the structural fluid sets to a solid overtime. The structural fluid may only attain structural capabilities onceit becomes a solid or ‘sets’.

The structural fluid may be concrete.

The structural fluid may be a thermoset polymer.

The structural fluid may give the structural cell its structuralcapabilities and resistance to compressive load.

The structural fluid may at least partly bear the load of a hardscapeplaced on the structural cell.

The structural fluid may at least partly bear a load applied by anobject on a hardscape placed over the structural cell.

Optionally, the structural cell may be separated from the structuralfluid once the fluid has set, the structural fluid taking the same formas the structural cell defining a similar free void space within the setstructural fluid shape.

Formwork Cell

In a second aspect, there is provided a structural cell formwork that isconfigured to receive and retain a structural fluid therein, thestructural cell comprising:

-   -   a plurality of hollow legs integrally linked to a frame at a        first frame end, the frame linking the legs together and the        frame defining a generally flat plane with the legs extending        substantially orthogonally away from the first frame end to a        leg terminal end; and    -   wherein the frame and hollow leg interior collectively define an        internal void space that receives and retains a structural fluid        placed therein.

As noted above, the internal void space may be at least approximately 1,or 2, or 3, or 4, or 5, or 6, or 7, or 8, or 9, or 10, or 11, or 12, or13, or 14, or 15, or 16, or 17, or 18, or 19, or 20, or 21, or 22, or23, or 24, or 25% of the overall structural cell volume. The structuralcell internal void space may be approximately 15-25%, or 10-15%, or5-10%, or 1-5% of the overall structural cell volume.

The internal void space may be substantially located within the hollowlegs.

The frame may comprise lateral supports linking the legs together aboutopen leg ends. The lateral supports and leg ends may together define acommon hollow that forms the entire internal void space. The commonhollow may instead be regions of the lateral supports and/or hollow legends. The common hollow may be segregated into different regions forexample using at least one spar or rib in the frame lateral supports orlegs.

As described elsewhere in this specification, the structural cell mayhave an additional structural fluid added and the structural cell itselfmerely acts to retain the structural fluid and does not itself provideany significant structural load capacity to the hardscape, instead onlyhaving sufficient strength to receive and retain structural fluid untilthe structural fluid is set.

A Cell Matrix Using Multiple Structural Cells

In a third aspect, there is provided a load bearing matrix comprising:

-   -   a plurality of structural cells aligned vertically and/or        horizontally; and    -   a plurality of separate plates, each separate plate being        approximately the same width and length as each structural cell,        the separate plates located on top of the plurality of        structural cells and/or below the plurality of structural cells;        and    -   wherein each structural cell comprises a plurality of legs        integrally linked to a frame at a first leg frame end, the frame        defining a generally flat plane with the legs extending        substantially orthogonally away from the first leg frame end to        a leg terminal end; and    -   wherein each separate plate comprises plate sockets linked        together via lateral connectors that engage with either an        opening in the first leg frame end of a first structural cell,        or the leg terminal end of a second structural cell.

The overall matrix volume may be defined by a free void space, aninternal void space and a portion of structural cell material itself,wherein:

-   -   the free void space of the matrix is the sum of each structural        cell free void space, this structural cell free void space being        the space defined by the frame width and depth and the leg        height less any space used within this volume for the legs or        frame parts and the internal volume defined by the legs and        frame; and    -   the internal void space of the matrix is the sum of each        structural cell internal void space, this structural cell        internal void space being any volume of space within the legs or        frame not accessible from the matrix free void space.

The matrix free void space may be at least approximately 75, or 76, or77, or 78, or 79, or 80, or 81, or 82, or 83, or 84, or 85, or 86, or87, or 88, or 89, or 90% of the overall matrix volume. The matrix freevoid space may be approximately 75-85%, or 80-85%, or 85-90% of theoverall matrix volume.

The matrix internal void space may be at least approximately 1, or 2, or3, or 4, or 5, or 6, or 7, or 8, or 9, or 10, or 11, or 12, or 13, or14, or 15, or 16, or 17, or 18, or 19, or 20, or 21, or 22, or 23, or24, or 25% of the overall matrix volume. The structural cell internalvoid space may be approximately 15-25%, or 10-15%, or 5-10%, or 1-5% ofthe overall matrix volume.

Cell Orientations

The frame may form a horizontal plane structural cell top and the legsextend substantially orthogonally from the structural cell frame in asubstantially vertical plane to provide the structural cell height. In amatrix, the structural cells may be aligned vertically with eachstructural cell frame being located above the legs (‘leg downorientation’).

Alternatively, the frame may form a horizontal plane cell bottom and thelegs extend substantially orthogonally from the cell frame in a verticalplane to provide the structural cell height, the legs terminating at apoint above the frame (‘leg up orientation’), this termination pointbeing the top of the structural cell. In a matrix, this leg uporientation may be one where the structural cells are aligned verticallywith each structural cell frame being located below the legs.

In a further alternative, the structural cells may be aligned inalternate orientation to form a matrix. For example, the structuralcells may be aligned vertically with each structural cell framealternating in orientation from a first layer of structural cells in aframe located below the legs configuration (leg up orientation) to asecond layer of structural cells in a frame located above the legsconfiguration (leg down orientation) and optionally, further alternatinglayers following the same alternating arrangement.

Optionally, the at least one separate plate may also be fittedintermediate first and second vertically stacked structural cellsvertically as well on the base or top of a matrix.

The choice of orientation of cell and matrix may be a combination offactors however, one governing factor may be the load to be taken by thecells and matrix and/or whether a structural fluid is used or not. Forexample, in low loading scenarios, it may be appropriate to stack thecells in a leg down orientation. In this case, the substrate facing sideof the cells (the leg ends) do not spread a load as much as the reverseleg up orientation hence the lower loading scenario. In medium to highload scenarios, it may be appropriate to orientate the cells in a leg upmanner so as to present a wide face (the frame side) of the cell to thesubstrate/ground and therefore provide greater load spreading. In highload scenarios it may be preferable to use an alternating configurationwith a leg up base layer and a leg down layer coming next, the ends ofthe structural cell legs in either cell layer meeting together. Leg downconfiguration or alternating leg up base layer and leg down next layerconfigurations may be useful where a structural fluid is used since thestructural fluid can be poured into the wider frame end and thestructural fluid pours down into the narrower legs and, in the case ofan alternating matrix, the structural fluid may pass through legopenings at the leg distal ends and fill out the leg up cell frameregion of the lower cell so as to give a larger substrate facingsurface. One advantage of the cell shape described herein and theability to orientate the cells in different ways is the ability of thematrix to deal with less than ideal substrates. Art products may dependon the substrate having been prepared, for example through compaction orthrough placement of a concrete surface, so that the art cell is appliedto an already hard and level surface. This may be to address point loadproblems where an unprepared surface may lead to unwanted sagging ormovement of the cell matrix about weaker or uneven regions. The cellsdescribed herein may, for example through leg up orientation do notrequire special substrate preparation since the frame of the cell hassufficient load spreading capability to avoid or minimise point loading.

Separate Plate General Structure and Function

The separate plate may be substantially planar comprising plate socketsand plate lateral supports linking the plate sockets together in adesired configuration.

The separate plate may be used to impart rigidity to a structural cell,for example retaining the leg terminal ends in a desired configurationeven when under compressive loading. As described further below, theseparate plate may comprise linkages that may be used to link to otherseparate plates and the thereby help confer greater rigidity andstrength to a matrix of structural cells.

Plate Socket and Plate Lateral Support Configuration

The position of the plate sockets and plate lateral supports maysubstantially mirror the configuration of the frame lateral supports andframe ends of the legs.

Specifically:

-   -   in a generally vertical planar leg configuration, each plate        lateral support may meet each plate socket at 180 degrees to        each other plate lateral support;    -   in a generally square or rectangular arrangement, each plate        lateral support may meet each leg end (frame or terminal leg        end) at right angles to each other plate lateral support;    -   each plate lateral support may be elongated and narrower in        width than the plate socket diameter;    -   each plate lateral support may have a width and/or depth that is        approximately 25, or 30, or 35, or 40, or 45, or 50, or 55, or        60, or 65 or 70, or 75% of the diameter of the plate socket;    -   each plate lateral support may have a length from plate socket        to plate socket that is approximately 50, or 55, or 60, or 65,        or 70, or 75, or 80, or 85, or 90, or 95, or 100, or 105, or        110, or 115, or 120, or 125, or 130, or 135, or 140, or 145, or        150% that of the diameter of the plate socket.

Plate Lateral Supports

The plate lateral supports may be ribbed elongated members.

The plate lateral supports may have a U-shaped or H-shaped crosssection.

Each plate lateral support may be linear and straight along the supportelongated length.

Alternatively, each plate lateral support may be non-linear and vary inpath along the support elongated length.

Each plate lateral support may have an arc shape along the supportelongated length.

Plate Socket Shape

The plate sockets may have a cross-sectional shape that substantiallycomplements and snugly fits the shape of the terminal end of each legand/or the shape of the frame end of each leg. Reference is made aboveto a socket diameter implying a circular socket shape. As should beappreciated, the plate socket shape may vary from circular and referenceto the term ‘diameter’ should not be seen as limiting.

The sockets may be collar shaped with a substantially circularcross-section.

The socket collar height may be approximately 10, or 15, or 20, or 25,or 30, or 35, or 40, or 45, or 50, or 55, or 60, or 65, or 70, or 75%that of the leg terminal end diameter. The socket collar height may beapproximately 10-75%, or 20-75%, or 40-60%, or approximately 50% that ofthe leg terminal end diameter.

The socket collar height may be approximately 10, or 15, or 20, or 25,or 30, or 35, or 40, or 45, or 50, or 55, or 60, or 65, or 70, or 75%that of the leg frame end diameter. The socket collar height may beapproximately 10-75%, 20-75%, or 40-60%, or approximately 50% that ofthe leg frame end diameter.

In one embodiment, the socket collar height may be approximately 2, or2.5, or 3, or 3.5, or 4, or 4.5, or 5, or 5.5, or 6 inches tall. In oneembodiment the height may be approximately 2-6, or 3-5, or around 4inches tall.

The socket collar height may be approximately the same irrespective ofuse or otherwise of the plate at the leg terminal ends or frame ends.

The plate sockets may have an open configuration so that, if astructural fluid is used, the structural fluid may pass through theplate sockets.

Plate Socket Fitting

Each plate socket may, if fitted to the frame, fit as a snug malefitting partly into the top female side of an opening in the leg frameend of a first structural cell. The opposing leg terminal end of asecond structural cell may fit as a male fitting into the opening(female side) of the plate socket. Reverse male/female configurations tothe above may also be used.

The socket collar may have frustroconical interior walls that allow theleg terminal end and/or leg frame end to mate snugly with the socketcollar interior or exterior walls depending on the male/femaleorientation used.

Each socket collar may be formed in two halves for example comprising:

-   -   a first female half with frustroconical interior walls cambered        so as to move from a wider opening diameter to a narrower        mid-diameter and;    -   a second male half with frustroconical exterior walls cambered        so as to move from a narrower opening diameter to a wider        mid-diameter.

The socket collar exterior or interior may include friction modifyingfeatures to increase the retention such as keying or roughened surfacesor features to decrease the retention such as smoothed surfaces ormaterial choices.

Plate Lateral Connectors

The, or each, separate plate may optionally have at least one lateralconnector used to link multiple plates across a common (e.g. horizontal)plane. When used with the structural cell described above, the separateplates may be used to provide a cell matrix with horizontal planestability acting to align the cells. These lateral connectors may beused in practice to connect abutting structural cells together. Theconnection may be about a substantially horizontal plane with no orminimal separation distance between the structural cells in the matrixother than the distance defined by the lateral connectors shape andform. The lateral connectors may, in one embodiment, have a shape andform that enables the legs of each structural cell in a matrix to besubstantially equidistant to each other.

The at least one lateral connector may extend from the separate platelaterally about a plane defined by the separate plate planar face.

Each separate plate may comprise a plurality of lateral connectors.

The separate plate lateral connectors may be integrally formed withother separate plate parts such as the plate lateral supports and/orplate sockets. The separate plate lateral connectors may not be separateparts.

Each separate plate may have at least one lateral connector extendingoutwardly from a plate perimeter.

The at least one lateral connector may extend outwardly in an orthogonaldirection from a plate lateral support.

A single lateral connector may extend from each plate lateral supportbetween plate sockets.

Each lateral connector may extend outwardly from a plate lateral supportapproximately 25, or 30, or 35, or 40, or 45, or 50, or 55, or 60, or65, or 70, or 75% the diameter of a plate socket.

Each lateral connector may terminate about the widest point of eachplate socket so that the lateral connector ending is approximately levelwith a separate plate edge defined by the maximum socket outer faceposition.

Each lateral connector may terminate with either a T-shaped member or aC-shaped member, the T-shape and C-shape substantially complementingeach other so as to join together.

In one embodiment, the separate frame may comprise a 3×3 socket squareshape and each outward facing plate lateral support comprises a lateralconnector extending therefrom. In this embodiment, the terminal end ofeach lateral connector may alternate between a T-shaped ending and aC-shaped ending on a first separate plate so as to complementalternating T-shaped or C-shaped endings of a further separate platelocated alongside the first separate plate.

Cell Lateral Connectors

As an alternative to the above (or in combination with the above), acell or cells may have lateral connectors extending from the cellside(s) to allow connection between abutting cells, typically about ahorizontal plane. The cell lateral connectors may extend for examplefrom the leg frame end.

The cell lateral connection may as noted above be about a substantiallyhorizontal plane with no or minimal separation distance between thestructural cells in the matrix other than the distance defined by thecell lateral connector shape and form. The cell lateral connectors may,in one embodiment, have a shape and form that enables the legs of eachstructural cell in a matrix to be substantially equidistant to eachother.

The at least one lateral connector may extend from the cell framelaterally about a plane defined by the upper planar surface of theframe.

Each cell may comprise a plurality of cell lateral connectors.

The cell lateral connectors may be integrally formed with the cell andmay extend the line generally defined by the connectors used to link thelegs of the frame. The cell lateral connectors may not be separateparts.

Each cell may have at least one lateral connector extending outwardlyfrom a cell frame perimeter.

The at least one cell lateral connector may extend outwardly in anorthogonal direction from a cell frame.

Each cell lateral connector may extend outwardly from a cell frameapproximately 25, or 30, or 35, or 40, or 45, or 50, or 55, or 60, or65, or 70, or 75% the diameter of a plate socket.

Each cell lateral connector may terminate with either a T-shaped memberor a C-shaped member, the T-shape and C-shape substantiallycomplementing each other so as to join together.

In one embodiment, the cell frame may comprise a 3×3 socket square shapeand each outward portion of the frame comprises a cell lateral connectorextending therefrom. In this embodiment, the terminal end of each celllateral connector may alternate between a T-shaped ending and a C-shapedending so as to complement alternating T-shaped or C-shaped endings of afurther cell located alongside the first cell.

Free Sockets

Optionally, separate free sockets may be used alone with no separateplate or plate lateral supports linking the free sockets.

In this embodiment, the free socket or free sockets may be used betweencells vertically so as to locate structural cells together. The freesockets may also provide a common spacing between structural cells.

The free sockets may align multiple structural cells vertically andprevent movement of a structural cell matrix.

The free sockets may be separate parts mated to the structural cells asrequired.

The matrix may further comprise at least one free socket placedintermediate vertical spaced structural cells, each free socket linkingtogether an opening in the frame end of a leg in a first structural cellwith the terminal end of a leg in a second structural cell.

Like for the separate plate, each free socket may fit as a snug malefitting partly into the top female side of an opening in the frame endof a leg in a first cell. The opposing terminal end of a leg in a secondcell may fit as a male fitting into the opening (female side) of thesocket. The reverse male/female configuration may also be possible.

The dimensions, form and function of the free socket may be largelyidentical to the plate socket and further details on this are providedabove and not repeated here.

The free sockets may, when placed inside the frame end of a leg, act toprovide a footing or stop inside a leg opening that the exterior of aterminal end of a next cell leg abuts and is supported on.

The free sockets may have an open configuration so that, if a structuralfluid is used, the structural fluid may pass through the free sockets.

Materials

The materials used to produce the structural cell above, the separateplate(s), and the free sockets may be selected from: plastics,composites, metals, metal alloys, and combinations thereof.

Plastics if used may optionally be reinforced. For example, the plasticsmay be reinforced using fibres such as glass fibres.

Plastics if used may be at least in part recycled plastic.

The structural cells, separate plates and free sockets may be mouldeditems.

Kits, Transport, Storage, Assembly

The structural cells, separate plates and free sockets may form a kit ofparts with or without a set of instructions. The kit of parts may bestored and transported in a disassembled form and assembled in situ.

In transport or storage, the structural cells may nest together, thelegs of one structural cell nesting into frame openings of the legs in asubsequent structural cell.

In transport or storage the separate plates may be stacked on top ofeach other.

The parts may be light weight and easy to transport and move. Forexample, each structural cell may be approximately 1, or 1.5, or 2, or2.5, or 3, or 3.5, or 4, or 4.5, or 5, or 5.5, or 6, or 6.5, or 7, or7.5, or 8, or 8.5, or 9, or 9.5, or 10 kg each. In one embodiment, eachstructural cell may weigh approximately 2 to 8 kg. In a furtherembodiment, each structural cell may weigh approximately 3 to 5 kg. Ifconcrete is poured into the structural cells as described further below,the structural fluid taking up the load imposed on the cell, the amountof structural cell material may be reduced, potentially to only thatneeded to retain the structural fluid in place prior to hardening. As aresult, the basic structural cell weight could be further reduced ifdesired.

The different parts may be assembled toolessly. That is, the parts donot require the use of separate fasteners, hand tools such as hammers orscrew drivers or power tools such as cordless drills in order to beassembled. Assembly uses a minimum of parts and can be completed withminimal training and experience.

In one embodiment, each structural cell in the matrix may approximatelyabut the other structural cell about a horizontal plane with no orminimal separation distance between the structural cells in the matrix.Each structural cell in the matrix may approximately abut the otherstructural cell about a horizontal plane so that the legs of eachstructural cell may be substantially equidistant to each other.Equidistant spacing may be achieved through use of extensions or widenedframe construction or the lateral connectors noted above so as to stillallow structural cell abutment but also impose a distance of separationbetween the structural cell legs. Separate linking members could also beused and reference to integral connectors or the lateral connectorsnoted earlier in this specification should not be seen as limiting.

Optionally, the matrix may further comprise at least one free socketplaced intermediate vertical spaced structural cells, each free socketlinking together an opening in the frame end of a leg in a firststructural cell with the terminal end of a leg in a second structuralcell.

Concrete Cell

In a fourth aspect, there is provided a structural cell formed fromhardened structural fluid, the structural cell comprising:

-   -   a plurality of solid legs linked to a frame at a first frame        end, the frame defining a generally flat plane with the legs        extending substantially orthogonally away from the first frame        end to a leg terminal end; and wherein the structural cell        defines a free void space therein, the free void space defined        by the frame width and depth and the leg height, less any space        used within this volume for the legs or frame parts.

Concrete Cell Matrix

In a fifth aspect, there is provided a load bearing matrix comprising:

-   -   a plurality of structural cells stacked vertically and/or        horizontally wherein each structural cell is formed as one        element from hardened structural fluid, each structural cell        comprising:    -   a plurality of solid legs linked to a frame at a first frame        end, the frame defining a generally flat plane with the legs        extending substantially orthogonally away from the first frame        end to a leg terminal end; and wherein the structural cell        defines a free void space therein, the free void space defined        by the frame width and depth and the leg height, less any space        used within this volume for the legs or frame parts.

In the above structural fluid cell and matrix, the structural fluid usedto form the structural cell may be poured into a structural cellformwork and the formwork remains with the structural cell. The formworkmay instead be removed once the structural fluid hardens.

The structural fluid in the above cell and matrix may be concrete.

The structural fluid in the above cell and matrix may be a thermosetpolymer.

The structural fluid in the above cell and matrix may give thestructural cell/matrix its structural capabilities and resistance tocompressive load.

Pouring of the structural fluid may occur in situ at or about the finalstructural cell or matrix position.

The structural cell and/or matrix described in the aspects above mayhave a compressive strength in excess of 300, or 400, or 500, or 600kPa. The structural cell and/or matrix described in the above aspectsmay have substantially no elastic deformation/deflection prior to thecompressive strength being reached.

Blanks

A cell or matrix may be fitted with a blank or blanks. In oneembodiment, a blank may be configured to cover part or all of the hollowin the cell frame and legs, the hollow being a fluid holding portione.g. internal void space, of the cell. Alternatively, a blank may beconfigured to cover part or all of the openings leading to the free voidspace inside the cell or matrix and block access to the internal voidspace. In a further embodiment, a blank may be configured to blockaccess from the top of the cell into either the free or internal voidscape of the cell or matrix.

The blank or blanks may be used for example to segregate the differentvoid spaces for example to allow the structural fluid to enter theinternal void space but be excluded from the free void space.Alternatively, the blank prevents substrate such as water or soilentering the internal void space and only allows access to the free voidspace. The blank may also be used to support foot traffic on the cell ormatrix and other items such as bar chairs for concrete placement.

Side Panels

As noted above, the cell(s) may be inserted into a pit or built aboveground. Side panels may be erected around the cell/matrix to provide asolid wall or walls around the cell/matrix and hence provide a boundaryfor where substrate such as soil or water may extend to from the freevoid space inside the cell or matrix.

Base Panel or Footing

Optionally, a cell or matrix of cells may comprise a base panel orsimilar footing or footings that are placed on a substrate and on whichthe cell/cells are placed thereon. The base panel or footing(s) may havesufficient structural properties to prevent movement of the cell(s) orpart thereof, particularly the cell(s) legs, when a compression load isplaced on the cell(s). The base panel or footing may also havesufficient structural properties to prevent localised displacement of apart or all of a cell or cells into the substrate or ground on which thecell(s) are placed. The structural properties noted may be strength tosupport a compressive load and rigidity to prevent or minimise relativedisplacement about the base panel or footing area.

Cell or Matrix Options

The above described structural cell or matrices may have service linesrunning through at least one structural cell or at least part of thematrix free void space.

Optionally, the at least one structural cell or at least part of thematrix may have a permeable or non-permeable wrap or barrier beneath,around or above the structural cell/matrix. This may be a geotextile,plastic wrap or other layer to separate the structural cell or matrixfrom the surrounding environment.

Optionally, the at least one structural cell or at least part of thematrix free void space may be at least partly back filled with asubstrate. The substrate may be selected from: soil or plant rootingmedia; filtration media; aggregate; and combinations thereof.

The soil if used may act as a growing medium for rooting plants. Thesoil may be uncompacted. The soil may be partly compacted.

Optionally, the at least one structural cell or at least part of thematrix may bear a load thereon. The load may be a static or dynamicload. The load may be a hardscape. The hardscape may be a road orpavement. The hardscape may have a load placed thereon such as people,vehicles, machinery and so forth.

Optionally, the at least one structural cell or at least part of thematrix free void space may be left open and clear of any othermaterials.

Optionally, the matrix may allow ingress of water into at least part ofthe matrix free void space. Egress of water from the structuralcell/matrix free void space or a part thereof may also be prevented orslowed. Ingress and prevention of egress may be a way to catch and storestorm water run off for alternative uses such as irrigation. Thisapplication and others are described in more detail below.

The legs of one structural cell in a matrix may substantially align withthe legs of a second and subsequent vertically stacked structural cellso as to provide a common transfer of compressive load down a single legcolumn from the top of a matrix to the bottom of the matrix. That is,there is a continuous alignment of the legs and transfer of compressiveload across successive structural cells.

Openings in the free void space of the matrix may be substantiallycontinuous from top to bottom or side to side of the matrix. That is,the openings in the free void space of one structural cell maysubstantially align with the openings in any additional structural cellsused.

A cell matrix described may also comprise at least one aeration line.The aeration line may extend vertically through the matrix spanning someor all of the structural cells therein.

Method

In a sixth aspect, there is provided a method of forming a load bearingmatrix, the method comprising the steps of:

-   -   select at least one structural cell substantially as described        above and a substrate on which the load bearing matrix will be        formed;    -   place separate plates on the substrate;    -   place a first layer of structural cells on the separate plates;    -   repeat placing of structural cell layers vertically until the        desired matrix height is reached;    -   place separate plates on top of the final structural cell layer;        and optionally,    -   lacing a load on the matrix.

Optionally, the linking the cells and/or separate plates may be linkedtogether via at least one lateral connector during the method above.

Optionally, barrier material may be positioned in the pit base or sidesbefore the first separate plate layer is placed onto the pit substrate.

Optionally, after fitting the first or other subsequent layer ofstructural cells in the matrix, free sockets and/or separate plates maybe fitted to the lower layer of structural cells before placement of afurther layer of structural cells thereon.

Optionally, where a structural fluid is used, the structural fluid maybe poured into the at least one structural cell during matrix assembly.

Applications

The cells and cell matrices described above may be used in a variety ofways both like traditional structural cells, as well as in newapplications, such as those where leg or other part deflection was anissue or limiting factor.

One example typical application may be to fill the cell void space withuncompacted soil so as to allow for tree root growth within the cellunder a hardscape such as a road or pavement. The cells and matricesdescribed may perform this function with or without concrete infill andthereby act in this traditional manner. An advantage though of the celldesign described over the art is that the material requirements of thedesign described are, in the inventor's experience, lower than artdesigns meaning a lower overall cell cost.

An alternative application may be to use the cell void space as a waterreservoir where the void space is used to capture and retain, or atleast partly retain, storm water. Retention of water (or other liquids)may be indefinite or, alternatively for a pre-determined period of time.Retention may be to provide a buffer, for example in stormwater drains,thereby reducing the impact of flash flood events on stormwatertreatment systems by limiting the flow of water to a stormwater system.The limited flow may be pre-set to a volume that the system can copewith and thereby avoiding flooding, unwanted outfall or otherundesirable events. Full retention may be used to store water for afuture time when water is needed e.g. for irrigation. Liquid egress fromthe structural cell or matrix may be through the cell or matrix base orwalls or even through an orifice. Retention may be achieved usingimpermeable layers around the outside of a structural cell volume or theoutside of a matrix. The impermeable layer may have areas that are opene.g. to an orifice or through a filter so as to direct egress of liquidfrom the matrix.

The cells or matrices may also be used as filters. For example,stormwater run off may enter cells/matrices and the cells/matrices maycontain filtration media. The stormwater in this example may passthrough the filter material and be purified or screened prior to releaseinto the ground or to a transport system post filtration. The sameprinciple could be used for bunding for example around petrochemicalstorage tanks (or used in the ground surrounding petrochemical storagetanks) as a means to capture and even treat a spill.

There can also be other uses for structural cells or matrices using thestructural cells where void space is needed in order to fill a volumeand where some degree of structural strength and integrity is required.One example might be in the construction of roadside berms, over bridgesand the like where structural cell matrices may provide an alternativeto transporting and delivery of significant volumes of infill. Anotherexample may be in the construction of bunding around tanks, hillscreening for privacy and security and so on.

Another cell/matrix volume fill application may be about firewalls orpartitions between building levels. Optionally the cell void space couldbe filled with flame retardant, service lines and so on.

A yet further application may be to provide a spacing between a buildingroof top and garden on the roof top, the cells and matrix formed fromthe cells providing both a structural level that can be walked on aswell as at least in part, a growing medium for trees or other largerrootball plants.

A yet further application of the cells and matrix described may be toreplace and/or supplement other load bearing materials in buildingfoundations. In recent times, at least in earthquake prone areas,domestic house foundations are constructed using so-called ‘rib raft’ or‘raft’ foundations that have load bearing members amongst polystyrene orother high volume materials as a filler. The cells and matricesdescribed herein may perform a similar function to the load bearingmembers and polystyrene fillers all from one matrix and, for example,only filling selected cells with concrete.

Advantages of the above cell and matrix are described above, however oneadvantage reiterated here may include elimination of any deflection ofthe legs or other parts when subjected to a compressive load. Deflectionusing art products may be small but this still may be of some importancewhen used beneath pavements subjected to unrestricted or dynamicvertical loads. If a brittle hardscape or higher load is used,deflection to any extent may be detrimental to the hardscape orsurrounding material. The structural cell described, particularly whenfilled with a structural fluid that hardens, may better withstandcompressive loads and completely avoid any deflection at all. Concretein particular represents a useful structural fluid since it is wellunderstood and widely used and accepted in structural applications. Thecells and matrices described may further allow for new applications anduses of structural cells thereby increasing the design versatility andusage.

The embodiments described above may also be said broadly to consist inthe parts, elements and features referred to or indicated in thespecification of the application, individually or collectively, and anyor all combinations of any two or more said parts, elements or features.

Further, where specific integers are mentioned herein which have knownequivalents in the art to which the embodiments relate, such knownequivalents are deemed to be incorporated herein as of individually setforth.

WORKING EXAMPLES

The above described structural cells, matrices and methods of assemblyare now described by reference to specific examples.

Example 1

FIGS. 1-14 illustrate various embodiments of one form of structural celland matrix.

As shown in at least FIG. 1 and FIG. 2 a structural cell generallyindicated by arrow 1 may be a combination of a plurality of legs 2integrally linked to a frame 3 at a first frame end 4, the frame 3linking the legs 2 together and defining a generally flat plane with thelegs 2 extending substantially orthogonally away from the frame 3 planeto a leg 2 terminal end 5. The structural cell 1 may also comprise aseparate plate 6 engaging the legs 2, the separate plate 6 comprisingsockets 7 linking via plate lateral supports 14, each socket 7 engagingthe leg 2 terminal ends 5. Alternatively, the sockets 7 engage the leg 2frame 3 ends 4.

FIG. 1 illustrates one matrix arrangement starting with a separate plate6 as a base, a cell 1 with legs 2 and a frame 3, then another separateplate 6, then a subsequent cell 1 with legs 2 and a frame 3, then toppedwith a further separate plate 6. FIG. 2 illustrates an alternativearrangement where the separate plate 6 is used again on the base and topof the matrix however, intermediate the cells lie free sockets 8, onesocket 8 for each leg 2 frame end 4. Note that a specific view of thefree socket 8 is shown in FIG. 6. The bottom side 9 of each free socket8 engages the top of a leg 2 at the frame 3 end 4 of a leg 2. Engagementis by a male/female fitting, the free socket 8 lower end fitting as amale fitting into the female opening of the leg 2. The upper cellterminal leg 2 ends 5 fit again via a male/female connection, in thiscase, the leg 2 terminal ends 5 fit as male fittings into the top side10 of the free socket 8.

The overall structural cell 1 shape best seen in FIG. 3, FIG. 4 and FIG.5 is defined by the extent of the frame 3 width, depth and the leg 2length. As shown in the Figures, there are no other items or partspresent about the structural cell 1 height other than the legs 2. Whenviewed side on such as the views shown in FIGS. 5, 9 and 14, eachstructural cell may present openings completely through the structuralcell or matrix between the legs 2.

The overall structural cell 1 volume is defined by a free void spacee.g. that between the cell 1 legs 2, an internal void space such as theopen space inside the legs 2 and frame 3 and a portion of structuralcell 1 material itself. The free void space is the space defined by theframe 3 width W and depth D and the leg 2 height H shown in FIG. 3, FIG.4 and FIG. 5 less any space used within this volume for the legs 2 orframe 3 parts and any internal void space within the legs 2 and frame 3.The internal void space may be defined by any volume of space within thelegs 2 or frame 3 not accessible from within the free void space. Asshould be appreciated, none of the leg 2 volume may be accessible fromthe free void space if the legs 2 are continuous in form along theirheight H for example being solid legs (not shown) or alternatively beinghollow legs 2 as shown in the Figures but without any openingsaccessible from inside the free void space. Alternatively, at least someof the leg 2 volume may be accessible to the free void space if the leg2 or legs 2 are hollow internally and if an opening exists in the legsides (not shown).

The hardscape (not shown) may be a road or pavement laid over the top ofa matrix, typically over the top of an uppermost separate plate 6.

The structural cell may have multiple legs 2, the legs 2 arrangedrelative to each other in regular or even patterns that collectivelyspread a compressive load placed thereon. The Figures illustrate cells 1with a total of nine legs 2 arranged in a 3×3 grid or square shape. Thisshould not be seen as limiting since a variety of other leg 2 numbersand configurations may also be used.

The legs 2 shown in the Figures are substantially round in cross-sectionand tubular in length having a frustroconical shape. The legs 2 may takeother shapes and forms not shown. The tubular legs 2 are widest aboutthe frame 3 end 4 and narrowest at the terminal end 5.

The legs 2 shown in the Figures are hollow and open at the frame 3 end 4with the terminal end 5 being closed. This may be a useful configurationwhen structural fluid hereafter referred to as being concrete is pouredinto the cells 1.

The legs 2 have a common length or height H. The leg 2 height H mayvary, in the embodiments illustrated being approximately 16-20 incheslong although this dimension may be varied depending on the desireddesign and end applications.

The structural cell 1 legs 2 and frame 3 as shown in the Figures are onematerial formed together i.e. integral.

The frame 3 comprises lateral supports 11 linking the frame 3 end 4 ofeach leg 2, the frame 3 as a whole defining a generally flat plane. Inthe Figures, the frame 3 flat plane is in a horizontal orientation butthis orientation may be angled (not shown) relative to a horizontalplane if desired (e.g. by up to 1, or 2, or 3, or 4, or 5 degrees), forexample to account for substrate angle variations such as uneven ground.

The frame 3 and lateral support 11 positioning defines the position ofeach leg 2 relative to each other leg 2, fixing the leg 2 in positionwithin the overall structural cell 1 volume.

In the square leg arrangement shown in the Figures, each frame 3 lateralsupport 11 meets each leg 2 frame 3 end 4 at approximately right angles(90 degrees) to each other lateral support 11.

Each lateral support 11 is elongated and narrower in width than frame 3end 4 leg 2 diameter size. Each lateral support 11 is linear andstraight along the elongated length.

Each lateral support 11 has a width that is approximately 50% of thediameter of the first frame 3 end 4 of the leg 2 however this width maybe varied.

Each lateral support 11 has a length from leg 2 frame 3 side to leg 2frame 3 side that is approximately 100% of the diameter of the frame 3end 4 of the leg 2.

In the 3×3 leg 2 square configuration shown in the Figures, the frame 3width and depth may be approximately 35-37 inches, or approximately 36inches square.

The overall cell 1 height H from the terminal end of a leg 2 to the topof the planar form defined by the top of the frame 3 such as a frame lipor lips 12 may be approximately 150 to 400% of the cell 1 leg 2 frame 3end 4 diameter. In the Figures, the overall cell 1 height is around16-19 inches or approximately 18 inches high.

The frame 3 lateral supports 11 and leg 2 frame 3 end 4 surrounds maycollectively define a common hollow generally shown by arrow 13 in FIG.3, this hollow 13 being equivalent to the internal void space notedabove. The hollow 13 is bound in the Figures by an extended lip or lips12 about the lateral supports 11 and/or leg 2 frame 3 end 4 surrounds.

The common hollow 13 as shown in the Figures is the entire volume withinall of the lateral supports 11 and leg 2 ends 4. The hollow 13 orhollows 13 define a volume that is capable of receiving and retainingconcrete (not shown) therein.

The extended lip or lips 12 of the frame 3 may end at a common point soas to form the frame 3 substantially planar finish. The extended lip orlips 12 follow the perimeter of all of the frame 3 lateral supports 11and leg 2 frame 3 endings 4.

The concrete (not shown) may be poured as a liquid or semi-liquid intothe hollow or hollows 13 optionally through the plate sockets 7 or freesockets 8 if used and the concrete sets to a solid over time.

As shown in FIGS. 1 and 2, the cells 1 may be orientated to have thecell 1 frame 3 at the top with the legs 2 extending below the frame 3.Multiple structural cells 1 are stacked vertically using this sameorientation with each structural cell frame 3 being located above thelegs 2.

Alternatively (not shown), the frame 3 may form the cell base and thelegs extend substantially upwardly from the cell 1 frame 3. Multiplestructural cells 1 may be stacked using this same orientation with eachstructural cell 1 frame 3 being located beneath the legs 2.

In a further alternative, best illustrated in FIGS. 9, 10 and 13,structural cells 1 stacked on one another may alternate in orientation.For example, a first structural cell 1 may be laid onto a substrate orseparate plate 6 frame 3 side down with the legs 2 extending verticallyupwards. A second structural cell 1 may then be placed onto the firststructural cell 1, the second structural cell 1 terminal leg 2 ends 5abutting and aligning with the first structural cell 1 terminal leg 2ends and the second structural cell 1 then finishing at a highest pointabout the structural cell 1 frame 3.

The separate plate 6 shown in various Figures but specifically in FIG. 7and FIG. 11 has lateral supports 14 may be ribbed elongated members. Theplate 6 lateral supports 14 may have a U-shaped or H-shaped crosssection best seen in FIG. 7. Each plate 6 lateral support 14 is linearand straight along the support 14 elongated length.

The plate 6 sockets 7 (and free sockets 8) may have a cross-sectionalshape that substantially complements and snugly fits the shape of theterminal end 5 of each leg 2 and/or the shape of the frame 3 end 4 ofeach leg 2.

The plate sockets 7 and free sockets 8 have substantially similarshapes, the shape best seen in FIG. 6 (a free socket 8 is shown howeverthe only difference is the presence of plate lateral supports in theplate socket 7). Each socket 7, 8 is collar shaped with a substantiallycircular cross-section. The socket 7, 8 collar height may beapproximately 25-75%, or 40-60%, or approximately 50% that of the leg 2terminal end 5 diameter.

The socket 7, 8 collar height may be approximately 25-75%, or 40-60%, orapproximately 50% that of the leg 2 frame 3 end 4 diameter.

Each plate 6 socket 7 or free socket 8 fits to the frame 3 as a snugmale fitting partly into the top female side of an opening in the frame3 end 4 of a leg 2 in a first cell 1. Alternatively, the opposingterminal end of a leg 2 in a second cell 1 may fit as a male fittinginto the opening (female side) of the plate 6 socket 7 or free socket 8.Reverse male/female configurations to the above may also be used.

The socket 7, 8 collar may have frustroconical interior walls that allowthe leg 2 terminal end 5 and/or leg frame end 4 to mate snugly with thesocket 7, 8 collar interior or exterior walls depending on themale/female orientation used.

Each socket 7, 8 collar may be formed in two halves best seen in FIG. 6for example comprising:

a first female half 9 with frustroconical interior walls cambered so asto move from a wider opening diameter to a narrower mid-diameter and;

a second male half 10 with frustroconical exterior walls cambered so asto move from a narrower opening diameter to a wider mid-diameter.

The internal mid-point between the socket 7, 8 halves may include ashoulder or narrowed diameter rib 15. The shoulder may run fully aroundthe interior circumference of the socket 7, 8.

As best seen in FIG. 7 and Detail D of FIG. 8, the separate plate 6 alsocomprises lateral connectors 16. The lateral connectors 16 are used tolink multiple plates 6 across a common (e.g. horizontal) plane. Whenused with the structural cell 1 described above, the separate plates 6may be used to provide a cell matrix with horizontal plane stabilityacting to align the cells 1.

The lateral connectors 16 extend orthogonally from the separate plate 6perimeter about a plane defined by the separate plate 6 planar face.

The separate plate 6 lateral connectors 16 are moulded with the separateplate 6.

Each lateral connector 16 terminates about the widest point of eachplate 6 socket 7 so that the lateral connector 16 ending isapproximately level with a separate plate 6 edge defined by the maximumsocket 7 outer face position marked X in FIG. 7.

Each lateral connector may terminate with either a T-shaped member 16Aor a C-shaped member 16B, the T-shape 16A and C-shape 16B substantiallycomplementing each other so as to join together when fitted together.

In one embodiment, the separate frame 6 may comprise a 3×3 socket 7square shape and each outward facing plate 6 lateral support 14comprises a lateral connector 16 extending therefrom. In thisembodiment, the terminal end 16A, 16B of each lateral connector 16 mayalternate between a T-shaped ending 16A and a C-shaped ending 16B on afirst separate plate 6 so as to complement alternating T-shaped 16A orC-shaped 16B endings of a further separate plate 6 located alongside thefirst separate plate 6.

The lateral connectors 16 may instead or in addition be located on thecell 1 frame 3 (not shown). In this embodiment, the lateral connectors16 may extend from the frame 3 frame end 4 outwardly to allow directconnection between cells 1.

The materials used to produce the structural cell 1, separate plate 6and free sockets 8 if used shown in the Figures may be plastic althoughother materials may be used.

As may be appreciated, the Figures illustrate a structural cell 1 thatmay be regarded as being a preformed formwork cell ready to receiveconcrete therein, this in the main being due to the presence of hollows13 in the frame and legs that are open at the frame end to receive andretain concrete poured therein. The structural cells shown could insteadbe closed with no hollows 13 for example and the embodiments shown inthe Figures should not be seen as limiting.

In an alternative embodiment not shown, the structural cell may beformed as one element from hardened concrete for placement below ahardscape. The concrete structural cell may take on the form provided bythe structural cell 1 prescribed by the form work shown in the Figures,the resulting concrete cell having a plurality of solid concrete legslinked to a concrete frame at a first frame end, the concrete framedefining a generally flat plane with the legs extending substantiallyorthogonally away from the concrete frame plane to a concrete legterminal ending; and wherein the concrete cell defines a free void spacetherein defined by the concrete frame width and depth and the leg heightless any space used within this volume for the legs or frame parts.

Pouring of the concrete if used into the structural cell 1 may occur insitu at or about the final structural cell 1 or concrete cell (notshown) position.

As should be appreciated, the concrete cells noted may also be arrangedto form matrices such as those illustrated in FIG. 1, FIG. 2, FIG. 9,FIG. 10 and FIG. 13.

The legs 2 of one structural cell 1 in a matrix may substantially alignwith the legs 2 of a second and subsequent vertically stacked structuralcell 1 so as to provide a common transfer of compressive load down asingle leg 2 column from the top of a cell 1 matrix to the bottom of thecell 1 matrix. That is, there is a continuous alignment of the legs 2and transfer of compressive load across successive structural cells 1.

Openings in the free void space of the matrix may be substantiallycontinuous from top to bottom or side to side of the matrix. That is,the openings in the free void space of one structural cell maysubstantially align with the openings in any additional structural cells1 used.

A matrix may be rapidly assembled as follows:

-   -   1. Excavate a pit in which the matrix is to be formed and        optionally line the pit base and/or sides with a permeable or        non-permeable layer;    -   2. Place separate plates 6 on the pit base substrate, linking        the separate plates 6 together via the lateral connectors 16;    -   3. Place a first layer of structural cells 1 on the separate        plates 6 aligning and fitting together the structural cell 1 leg        2 terminal ends 5 or frame ends 4 depending on the structural        cell 1 orientation (frame 3 side up or down) with the separate        plate 6 sockets 7;    -   4. Repeat fitting structural cell 1 layers until the desired        matrix height is reached optionally including further        intermediate separate plates 6 between the structural cell 1        layers or including free sockets 8 between the structural cell 1        layers;    -   5. Place separate plates 6 on top of the final structural cell 1        layer, linking the separate plates 6 together via the at least        one lateral connector 16; and    -   6. Placing a hardscape on the matrix.

Where a concrete is used, the concrete may be poured into the at leastone structural cell 1 during matrix assembly, for example as eachstructural cell layer is fitted or once the whole matrix is assembled,the concrete being poured through the top most separate plate 6 sockets7 and running down each cell 1 layer assuming openings are present,usually between the structural cell 1 legs 2 to allow flow of concreteacross multiple structural cell 1 layers.

Aspects of the structural cells, matrices and methods of assembly havebeen described by way of example only and it should be appreciated thatmodifications and additions may be made thereto without departing fromthe scope of the claims herein.

What is claimed is:
 1. A structural cell formwork that is configured toreceive and retain a structural fluid therein, the structural cellformwork comprising: a plurality of hollow legs integrally linked to aframe at a frame end, the frame linking the legs together and the framedefining a generally flat plane with the legs extending substantiallyorthogonally away from the frame end about the frame flat plane to a legterminal end; and wherein the frame and hollow leg interior collectivelydefine an internal void space that receives and retains the structuralfluid placed therein; wherein the frame links the legs together vialateral supports located about the frame end of each leg with the framedefining a free void space between the lateral supports and the legswith the free void space being continuous and not segmented; and whereinthe lateral supports, leg frame end surrounds and legs collectivelydefine a common hollow, the common hollow defining an internal voidspace configured to receive and retain the structural fluid with theinternal void space being continuous and not segmented.
 2. A structuralcell formwork as claimed in claim 1 further including a separate plateengaging the legs, the separate plate comprising: linked sockets, eachsocket engaging the leg terminal end; and/or linked sockets, each socketengaging the leg frame ends or a part thereof.
 3. The structural cellformwork of claim 1 wherein the overall structural cell formwork volumeis defined by a free void space, an internal void space and a portion ofstructural cell formwork material itself, wherein: the free void spaceof the structural cell formwork comprises at least 75% of the overallstructural cell formwork volume, the free void space being defined bythe frame width and depth and the leg height less any space used withinthis volume for the legs or frame parts and the internal volume definedby the legs and frame; and the internal void space of the structuralcell formwork comprises approximately 1-25% of the overall structuralcell volume, the internal void space being defined by any volume ofspace within the legs or frame not accessible from the free void space.4. The structural cell formwork of claim 1 wherein the hollow legs ofthe structural cell formwork have, at least in part, a frustoconicalshape, the legs arranged relative to each other in regular or evenpatterns that collectively spread a compressive load placed thereon. 5.The structural cell formwork of claim 1 wherein the legs are at leastpartially open at: the frame end; the leg terminal end; or both the legframe end and the leg terminal end.
 6. The structural cell formwork ofclaim 1 wherein the common hollow defines a volume configured to receiveand retain a structural fluid therein.
 7. A load bearing matrix formedfrom the structural cell formwork of claim 1 comprising a plurality ofstructural cells aligned vertically and/or horizontally.
 8. The loadbearing matrix of claim 7 wherein the overall matrix volume is definedby a free void space, an internal void space and a portion of structuralcell material itself, wherein: the free void space of the matrix is atleast approximately 75%, the free void space being the sum of eachstructural cell free void space, this structural cell free void spacebeing the space defined by the frame width and depth and the leg heightless any space used within this volume for the legs or frame parts andthe internal volume defined by the legs and frame; and the internal voidspace of the matrix is approximately 1-25%, the internal void spacebeing the sum of each structural cell internal void space, thisstructural cell internal void space being any volume of space within thelegs or frame not accessible from the matrix free void space.
 9. Theload bearing matrix of claim 7 wherein the structural cells are alignedvertically with each structural cell frame being located above the legs.10. The load bearing matrix of claim 7 wherein the structural cells arealigned vertically with each structural cell frame being located belowthe legs.
 11. The load bearing matrix of claim 7 wherein the structuralcells are aligned vertically with each structural cell frame alternatingin orientation from a first layer of structural cells in a frame locatedbelow the legs configuration to a second layer of structural cells in aframe located above the legs configuration and optionally, furtheralternating layers following the same alternating arrangement.
 12. Theload bearing matrix of claim 7 wherein the matrix further comprises atleast one free socket placed intermediate vertically spaced structuralcells, each free socket linking together an opening in the leg frame endin a first structural cell with the leg terminal end of a secondstructural cell.
 13. A structural cell formed from hardened structuralfluid, the structural cell produced using the cell formwork of claim 1wherein the structural cell free void space is defined by the framewidth and depth and the leg height, less any space used within thisvolume for the legs or frame parts.
 14. The structural cell of claim 13wherein the structural fluid used to form the structural cell is pouredinto the structural cell shaped formwork and the structural cellformwork remains with the structural cell.
 15. The structural cell ofclaim 13 wherein the structural fluid is concrete.
 16. The structuralcell of claim 13 wherein pouring of the structural fluid into thestructural cell formwork occurs in situ at or about the final structuralcell position.
 17. A load bearing matrix comprising a plurality of thestructural cells of claim 13 aligned vertically and/or horizontallytogether.
 18. The load bearing matrix of claim 17 wherein at least partof the structural cell free void space is at least partly back filledwith substrate selected from: soil or plant rooting media; filtrationmedia; aggregate; and combinations thereof.
 19. The load bearing matrixof claim 17 wherein at least part of structural cell free void space isleft open and clear of any other materials.
 20. The load bearing matrixof claim 17 wherein the matrix allows ingress of water into at leastpart of the structural cell free void space and the matrix prevents orslows egress of water from the structural cell free void space or a partthereof.
 21. The load bearing matrix of claim 7 wherein the matrixcomprises a plurality of separate plates, each separate plate beingapproximately the same width and length as each structural cell, theseparate plates located on top of the plurality of structural cellsand/or below the plurality of structural cells; and wherein eachseparate plate comprises plate sockets linked together via lateralconnectors that engage with either an opening in the frame end of afirst structural cell, or the leg terminal end of a second structuralcell.
 22. The structural cell of claim 13 wherein the structural cellhas a compressive strength in excess of 300 kPa.
 23. The structural cellof claim 22 wherein the structural cell has substantially no elasticdeformation/deflection prior to the compressive strength being reached.24. The structural cell of claim 22 wherein the structural cell formworkhas a compressive strength of less than 200 kPa alone but, a hardenedstructural fluid and formwork combination or a hardened structural fluidwith the formwork removed post hardening, has a compressive strength inexcess of 300 kPa.
 25. The structural cell of claim 22 wherein thestructural cell formwork flexes if a compression load is placed thereonin the absence of a structural fluid but, if hardened structural fluidis present in the formwork, the formwork and hardened structural fluidwill not flex or elastically deform until or substantially around themaximum compressive strength of the hardened structural fluid.
 26. Theload bearing matrix of claim 21 wherein the at least one separate plateis fitted intermediate the first and second vertically alignedstructural cells.
 27. The load bearing matrix of claim 21 wherein theplate sockets have a cross-sectional shape that substantiallycomplements and snugly fits the shape of the terminal end of each legand/or the shape of the frame end of each leg.
 28. The load bearingmatrix of claim 21 wherein each plate socket when fitted to the frame,fits as a snug male fitting partly into a top female side of an openingin the leg frame end of a first structural cell and the opposing legterminal end of a second structural cell fits as a male fitting into theopening of the top female side of the plate socket.
 29. The load bearingmatrix of claim 21 wherein each separate plate has at least one lateralconnector used to link multiple plates across a common horizontal plane.30. The load bearing matrix of claim 29 wherein the at least one lateralconnector connects abutting structural cells together, the lateralconnectors having a shape and form that enables the legs of eachstructural cell in the matrix to be substantially equidistant to eachother.